WABCO OptiTire User guide

OPTITIRETM
TIRE PRESSURE MONITORING
FOR COMMERCIAL VEHICLES
SYSTEM DESCRIPTION

Table of contents
Original document:
The German version of this document is the original document.
Translation of the original document:
All non-German language editions of this document are translations of
the original document.
Edition 2 (08.2019)
Document number: 815 010 229 3 (en)
You will nd the current edition at:
http://www.wabco.info/i/533

3
Table of contents
Table of contents
1 List of abbreviations ........................................................................................................................................ 5
2 Symbols used................................................................................................................................................... 6
3 Safety information............................................................................................................................................ 7
4 Introduction ...................................................................................................................................................... 8
5 System description ........................................................................................................................................ 10
5.1 Basic OptiTire function.......................................................................................................................... 10
5.2 Conguration for bus and towing vehicle.............................................................................................. 11
5.3 Conguration for trailers........................................................................................................................ 14
5.3.1 OptiTire in trailer operation...................................................................................................... 18
5.4 Expert’s report / certicates .................................................................................................................. 19
5.4.1 ATEX ....................................................................................................................................... 19
5.4.2 Radio approvals ...................................................................................................................... 19
5.4.3 OptiTire RF declaration of conformity...................................................................................... 20
6 Components ................................................................................................................................................... 21
6.1 Sensors................................................................................................................................................. 21
6.1.1 The external sensor (WM2)..................................................................................................... 22
6.1.2 The internal sensor (WIS) ....................................................................................................... 27
6.1.3 The internal sensor (SMS) ...................................................................................................... 30
6.2 ECU – The electronic control unit ......................................................................................................... 31
6.3 WABCO display .................................................................................................................................... 32
6.4 Connecting cables ................................................................................................................................ 32
6.7 WABCO TPMS Manager ...................................................................................................................... 39
7 Installation ...................................................................................................................................................... 41
7.1 Safety information................................................................................................................................. 41
7.3 Assembly of the internal sensor WIS.................................................................................................... 45
7.4 Assembly of the internal sensor SMS................................................................................................... 48
7.5 Assembly of the tire .............................................................................................................................. 51
7.6 Mounting the ECU in bus / towing vehicle ............................................................................................ 52
7.7 Wiring in towing vehicle/bus.................................................................................................................. 54
7.8 Mounting the ECU in the trailer............................................................................................................. 55
7.9 Wiring in trailer...................................................................................................................................... 57
8 Requirements for start-up ............................................................................................................................. 58
8.1 Training ................................................................................................................................................. 58
8.2 Diagnostic Software.............................................................................................................................. 58
8.3 Diagnostic hardware ............................................................................................................................. 59
8.4 Installing the Diagnostic Software......................................................................................................... 59
9 Start-up ........................................................................................................................................................... 60
9.1 Starting the Diagnostic Software........................................................................................................... 60
9.2 Parameter setting.................................................................................................................................. 60
9.2.1 Reading in a parameter set..................................................................................................... 60

4
Table of contents List of abbreviations
9.2.2 Selection/entry of parameter data ........................................................................................... 60
9.2.3 Stimulating the sensors........................................................................................................... 61
9.2.4 Warninglampconguration..................................................................................................... 62
9.2.5 Change ECU address (Trailer Train) (Trailer ECUs only)........................................................ 62
9.2.6 Country-specicadjustments .................................................................................................. 62
9.2.7 Expert parameters................................................................................................................... 63
9.3 Module reception .................................................................................................................................. 64
9.4 Assignment test .................................................................................................................................... 64
9.5 Finalising start-up.................................................................................................................................. 64
10 Operation ........................................................................................................................................................ 65
10.1 Warning signals..................................................................................................................................... 65
10.2 Switching on of ignition ......................................................................................................................... 65
10.3 Checking pressure values..................................................................................................................... 66
10.4 Display of faults..................................................................................................................................... 67
10.5 Adjusting tire pressures ........................................................................................................................ 69
10.6 Display of system errors ....................................................................................................................... 69
10.7 Display via SmartBoard ........................................................................................................................ 71
11 Workshop notes ............................................................................................................................................. 72
11.1 Maintenance ......................................................................................................................................... 72
11.2 Replacement and repair........................................................................................................................ 72
11.2.1 Replacing an IVTM ECU with an OptiTire ECU ...................................................................... 72
11.2.2 Replacing 1st generation external sensor with a 2nd generation sensor................................ 72
11.2.3 Wheel change ......................................................................................................................... 72
11.2.4 Replacing PA tubes (external sensor) .................................................................................... 74
11.2.5 Creeping pressure loss ........................................................................................................... 74
11.2.6 No signal received from the sensor......................................................................................... 75
12 Disposal .......................................................................................................................................................... 77
13 WABCOregionalofces................................................................................................................................ 78

5
List of abbreviations
1 List of abbreviations
ABBREVIATION MEANING
ADR (French: Accord européen relatif au transport international des marchandises Dangereuses par
Route); European agreement concerning the international carriage of dangerous goods by road
CAN Controller Area Network; asynchronous serial bus system for networking control units in vehicles
ECAS Electronically Controlled Air Suspension
ECU Electronic Control Unit
GND Ground; earth
ID Identier
TEBS Electronic Braking System for Trailers
VCS Vario-Compact-System; compactly structured ABS for trailers
WIS Wheel Internal Sensor
WM2 Wheel Sensor 2; external wheel sensor or module
SMS Strap Mounted Sensor; internal (wheel) sensor module
TPMS Tire Pressure Monitoring System
UDS Unied Diagnostic Services
VIN Vehicle Identication Number

6
Symbols used
2 Symbols used
Symbols used
DANGER
The signal word denotes a hazard with a high degree of risk which, if not avoided, will result in death
or serious injury.
WARNING
The signal word denotes a hazard with a medium degree of risk which, if not avoided, can result in
death or serious injury.
CAUTION
The signal word denotes a hazard with a low degree of risk which, if not avoided, may result in minor
or moderate injury.
NOTICE
The signal word denotes a hazard which, if not avoided, can result in material damage.
Important information, notes and/or tips
Reference to information on the internet
Descriptive text
–Action step
1. Action step 1 (in ascending order)
2. Action step 2 (in ascending order)
ÖConsequence of an action
Listing
• Listing
Note on the use of a tool / WABCO tool

7
Safety information
3 Safety information
Observe all necessary regulations and instructions:
Read this document carefully.
Adhere to all instructions, information and safety information to prevent injury to persons and
damage to property.
WABCO will only guarantee the safety, reliability and performance of their products and systems if
all the information in this publication is adhered to.
Always abide by the vehicle manufacturer's specications and instructions.
Observe all accident regulations of the respective company as well as regional and national
regulations.
Make provisions for a safe work environment:
Only trained and qualied technicians may carry out work on the vehicle.
Use personal protective equipment if required (safety goggles, respiratory protection, ear protectors,
etc.).
Ensure that the workplace is dry and provided with sufcient lighting.
Pedal actuations can lead to severe injuries if persons are in the vicinity of the vehicle. Make sure
that pedals cannot be actuated as follows:
– Switch the transmission to "neutral" and actuate the park brake.
– Secure the vehicle against rolling by using chocks.
– Fasten a note clearly visible to the steering wheel indicating that work is being performed on the
vehicle and that the pedals are not to be actuated.

8
Introduction Introduction
4 Introduction
This document describes the function and installation of the OptiTire tire pressure monitoring system.
WABCO OptiTire is the next generation of tire pressure monitoring for commercial vehicles and
replaces the predecessor system IVTM.
OptiTire was specially developed to reduce the running costs for eets and increase safety.
Reduce downtimes and extend tire life
The need to maintain the correct tire pressure seems self-evident, but in reality the tire pressure is
checked far too infrequently. Lack of time, inattention and complacency are some of the reasons for
this. An ofcial study has found that more than 30 % of all truck breakdowns are caused by tire issues.
Further studies have shown that over or under ination of 15% can reduce the life of a tire by more than
10 %.
With under-inated tires there is an increased risk of sustained overheating. This can cause terminal
damage to the casing. WABCO OptiTire helps to maintain the correct tire pressure and to detect slow
punctures early.
Downtimes
Tire damage is the most frequent reason for commercial vehicle vehicles to be out of service.
Tires
32 %
Electrics
29 %
Engine
21 %
Other
2 %
Consumables
4 %
Brakes
6 %
Cut fuel costs and minimise CO2emissions
Fuel is the largest variable cost for eet operators. With diesel prices more frequently going up than
down, fuel economy is of paramount importance.
Studies by the tire industry have conrmed that the increased rolling resistance of under-inated tires
has a negative impact on fuel consumption and increases CO2emissions. Tires that maintain the
correct air pressure, on the other hand, can reduce fuel consumption by up to 2 % and reduce CO2
emissions.

9
Introduction
Fuelefciency
A constantly 17 % under-inated tire leads up to 1,400 litres increase in fuel consumption (200,000 km
annual mileage for long haul applications).
0%
-2%
10%
-10%-20%-30%
20% 30%
2%
4%
6%
8%
-40%-50%
10%
-60%
Pressure too high
Pressure too low
Deviation from recommended tire pressure (%)
Changes in fuel consumption (%)
Life of the tires
A deviation of 15 % from the recommended tire pressure reduces the life of a tire by more than 10 %.
0%
-10%
10%
-5%-15%
-20%
-25%-30% 15%
-20%
20%
-30%
25%
-40%
30%
5%-10%
-50%
Pressure too high
Pressure too low
Reduction of tire life (%)
Deviation from recommended tire pressure (%)
Reduce risk and improve safety
Incorrect tire pressure is dangerous and may entail the following risks:
A tire failure.
A deterioration in vehicle handling.
An extended braking distance.
WABCO’s OptiTire helps maintain tire pressure at the recommended level, preventing tire damage and
enhancing eet safety.
OptiTire cannot announce sudden, extreme tire damage caused by external effects.

10
System description System description
5 System description
This chapter describes the conguration and how the OptiTire system operates. Furthermore, you will
also obtain information concerning technical reports for installing and retrotting.
5.1 Basic OptiTire function
A B A A BA A
C
A1 A2 A3 B C
LEGEND
ASensors:
External sensor WM2 (A1) or internal sensor WIS (A2) or internal sensor SMS (A3)
BElectronic Control Unit (ECU)
CDisplay
Measurement
The tire pressure is measured by sensors, the values obtained are repeatedly transmitted to the
electronic control unit via a radio signal
The actual tire pressure of each wheel is transmitted to a central ECU. The signals of all wheels are
evaluated there and the information is conveyed to a display in the driver's cab.
Evaluating
In the ECU, the measured values are compared to one another and to standard values stored as a
parameter set in the ECU.
A single OptiTire ECU can monitor up to 20 wheels + 2 spare wheels. Dual tires are measured
separately.
A warning signal is activated in the event of a critical deviation.
Normal pressure uctuations due to driving style, outside temperature changes or load are ltered.
The OptiTire system tolerates these typical pressure uctuations even on poor road sections or with
uneven load.

11
System description
Display
WABCO offers a driver's display for the dashboard for indicating warning messages and requesting tire
pressure information.
Alternatively the data can also be transmitted to an integrated display, SmartBoard or
TX-TRAILERGUARDTM (telematics). Detailed description of the display function in Chapter "10
Operation", page 65.
5.2 Congurationforbusandtowingvehicle
Selection of OptiTire components depends on vehicle type, type and number of wheels and type of
systems connected to OptiTire but not on the vehicle system voltage.
ECU
Trucks, buses or articulated buses are equipped with the ECU (WABCO part number: 446 220 100 0).
Display
In the case of original equipment, the tire pressures are retrieved by a central on-board computer via
CAN and displayed on an integrated display in the dashboard.
If retrotted, the WABCO display (WABCO part number: 446 221 000 0) is used for retrieving the tire
pressures.
Sensors
Select sensors, corresponding connection hoses and counterweights according to their axle
conguration.
The table contains components for three vehicle type as examples. You will nd more information in
Chapter "6 Components", page 21.
WABCOBridgecongurator
WABCO offers an online congurator "WABCO Bridge" for the conguration of OptiTire for
different vehicles (towing vehicle, bus, and semitrailer).
– Open the myWABCO website:
http://am.wabco-auto.com/welcome/
Help on logging in can be obtained by pressing the Step-by-step instructions button.
After the successful registration you can use the online congurator WABCO Bridge via
myWABCO to carry out your own conguration of the OptiTire system.
Please contact your WABCO partner if you have any questions.

12
System description System description
Example: Parts list for bus / towing vehicle (with external sensors WM2)
WABCO PART
NUMBER COMPONENT COMMENT 4X2 6X2
ARTICULATED
BUS 6X2
446 220 100 0 ECU Communication with trailer ECU /
warning lamps
1 1 1
446 220 000 4 Mount Support for mounting the ECU 1 1 1
446 221 000 0 Display Display of warning messages and
retrieving tire pressures
1 1 1
894 607 390 0
+ adapter
894 600 001 2
Wiring harness Cable set 7-pin
optional 894 607 295 0 (5-pin, no
trailer operation)
1 1 1
960 731 051 0 External sensor,
L-shape
For front axle, rim 22.5", 10 holes 2 4 2
960 731 031 0 External sensor For rear axle, rim 22.5", 10 holes 4 4 8
960 905 822 4 Weight plate Counterweights for front axle sensor 2 4 2
960 731 802 0 PA tube For front axle sensor, L-shape 2 4 2
960 731 822 2 PA tube For rear axle sensor, outside 2 2 4
960 731 804 0 PA tube For rear axle sensor, inside 2 2 4
960 731 801 0 PA tube Super Single 2 2 4
Example: Parts list for bus / towing vehicle (with internal sensor WIS)
WABCO PART
NUMBER COMPONENT COMMENT 4X2 6X2
ARTICULATED
BUS 6X2
446 220 100 0 ECU Communication with trailer ECU /
warning lamps
1 1 1
446 220 000 4 Mount Support for mounting the ECU 1 1 1
446 221 000 0 Display Display of warning messages and
retrieving tire pressures
1 1 1
894 607 390 0
+ adapter
894 600 001 2
Wiring harness Cable set 7-pin
optional 894 607 295 0 (5-pin, no
trailer operation)
1 1 1
960 732 000 0 Internal sensor Internal sensor to be attached to a
special valve set
68 10
960 732 100 0 Valve set Exact design of the valve depends on
the rim
68 10

13
System description
Example: Parts list for trailer (with internal sensor WIS)
WABCO PART
NUMBER COMPONENT COMMENT
SEMITRAILER
(3-AXLE)
SINGLE
TIRES
SEMITRAILER
(3-AXLE)
TWIN
TIRES
446 220 110 0 ECU Communication with trailer ECU /
warning lamps
1 1
446 220 000 4 Mount Support for mounting the ECU 1 1
449 913 050 0
+ adapter
894 600 001 2
Wiring harness Wiring harness 7-pin
for connection to TEBS E
1 1
960 733 000 0 Internal sensor Internal sensor to be attached with a
strap
612
960 733 122 0 Fastening strap
22.5"
Fastening strap for 22.5" rims 612
Circuit diagrams
– Open the WABCO Webshop:
https://webshop.wabco-auto.com/webshop/
– Search the desired circuit diagram by entering the 10 digit number:
841 801 970 0 (solobus)
841 801 971 0 (articulated bus)
841 801 972 0 (tractor/truck)

14
System description System description
5.3 Congurationfortrailers
Transmission types
To display the OptiTire data of the trailer in the driver’s cabin, both the trailer and towing vehicle must be
equipped with OptiTire in combination with the external sensor WM2 if communication is implemented
via radio link.
Alternatively, the trailer data can be displayed in the towing vehicle if it is equipped with an integrated
display. When the trailer is also equipped with WABCO Trailer EBS, the data can be transferred to the
towing vehicle’s central computer via CAN.
The following illustrations compare both transmission types, wireless connection and CAN bus, with
each other.
Data transmission via a CAN bus
Data transmission via radio link
The data can only be transmitted via a radio link if both the towing vehicle and the trailer are
equipped with external sensors.
LEGEND
ADisplay
BSensors
CECU
DWireless connection
ETrailer ECU
FIntegrated display
GCentral computer
HTEBS modulator
*) In combination with external sensor in towing vehicle and trailer

15
System description
Stand-alone trailer towing operation
If the trailer should be independently equipped with OptiTire, the pressure release can be carried out
via telemetry or the vehicles own display. When using the OptiTire display, it requires a special box for
splash protection or another protected installation position. The WABCO SmartBoard can be installed
as an alternative.
The driver cannot receive fault messages without OptiTire support while the towing vehicle is in motion.
OptiTire with several trailers
It is possible to equip tractor/trailer combinations with more than one trailer. Trains with two trailers
can even be implemented with radio links, for road trains a CAN bus connection with special ECUs is
required.
Please contact your WABCO partner for more information.
OptiTire with TEBS D or TEBS E
The installation in a vehicle with TEBS D or TEBS E is simple because in this case only pre-assembled
cables need to be plugged in. Other systems would require open wiring that needs to be enclosed by
protective housing.

16
System description System description
Wiring diagrams for trailers
Circuit diagrams
– Open the WABCO Webshop:
https://webshop.wabco-auto.com/webshop/
– Search the desired circuit diagram by entering the 10 digit number.
If the OptiTire system is installed instead of the IVTM system, additionally use the adapter
cable with the WABCO part number: 894 600 001 2 required.
Circuit diagram 841 801 943 0 "Trailer ABS VCS"
Cable position 8 (WABCO part number: 449 314 XXX 0)
is opened and connected to cable position 3 (WABCO
part number: 449 674 273 0) and a line to the stop light.
Circuit diagram 841 801 941 0 "Trailer EBS without
CAN connection"
Cable position 8 (WABCO part number: 449 614 XXX 0)
is opened and connected to cable position 3 (WABCO
part number: 449 674 273 0) and a line to the stop light.
The ISS output must not be used and needs to be set to
0 km/h.
Circuit diagram 841 801 945 0 "Trailer EBS D with
CAN"
Connection is implemented using cable position
3 (WABCO part number: 449 377 XXX 0 /
449 378 XXX 0).
The ISS output must not be used and needs to be set to
0 km/h.
The OptiTire diagnosis is carried out using diagnostic
cable 446 300 329 2 via the Trailer EBS diagnostic port.

17
System description
Circuit diagram 841 801 940 0 "Trailer ECAS"
The cable position 3 (WABCO part number:
449 674 273 0) is fed into bottom box of the ECAS-ECU
and connected there.
One cable to stop light (position 7) is installed
additionally.
You need screwed cable glands (PG 11: 894 130 312 2)
for two cables.
Circuit diagram 841 801 913 0 "Trailer EBS D with
CAN and SmartBoard"
(from year of manufacture 2004)
The SmartBoard and OptiTire are connected to the
Trailer EBS D modulator on port IN/OUT2.
CAN2 must be activated via the Diagnostic Software.
1. Trailer EBS D modulator
(WABCO part number: 480 102 014 0)
2. Cable family
(WABCO part number: 449 377 XXX 0)
3. SmartBoard
(WABCO part number: 446 192 110 0)
4. OptiTire ECU
5. Distributor housing
Circuit diagram 841 802 066 0 "Trailer EBS E"
The circuit diagram shows different connection options
with Trailer EBS E.
1. Standard TEBS E (WABCO part number:
480 102 03X 0)
2. Premium TEBS E (WABCO part number:
480 102 06X 0)
3. Multi-Voltage TEBS E (WABCO part number:
480 102 08X 0)
4. OptiTire ECU (WABCO part number:
446 220 110 0)
5. SmartBoard (WABCO part number:
446 192 11X 0)
6. Cable (WABCO part number: 449 913 XXX 0)
7. Cable (WABCO part number: 449 916 XXX 0)
8. Adapter cable (WABCO part number:
894 600 001 2)
9. Cable (WABCO part number: 449 627 XXX 0)
Additional GIO5 options

18
System description System description
5.3.1 OptiTire in trailer operation
Operating mode
The OptiTire system in the trailer operates self-sufciently if supplied with power.
Tire pressures can be displayed with the SmartBoard. In addition, the tire pressure information is
transmitted to the towing vehicle via the ISO 7638 CAN connection.
Not all towing vehicles display the tire pressures transmitted via CAN in the dashboard. Please
contact the manufacturer of the towing vehicle if you have any questions on this subject.
Alternatively, the tire pressures of the trailer can be transmitted by a radio signal to an OptiTire system
in the towing vehicle.
This wireless transmission can only occur if the external sensors are congured on both vehicles.
Apart from the display of trailer tire data in the towing vehicle, this data can also be transmitted directly
to the haulage company by means of telematics. The combination of OptiTire with
TX-TRAILERGUARDTM is of particular interest if the trailer is transported by subcontractors or
rented to third parties.
Automatic trailer recognition
The towing vehicle ECU automatically detects the combination with a trailer ECU: The stop light is
enabled on the towing vehicle and trailer when actuating the brake. The trailers ECU sends a radio
signal with the voltage pulse that is expected by the towing vehicle's ECU that instant. The towing
vehicle thus clearly detects that the trailer belongs to the tractor/trailer combination and subsequently
transmits trailer ECU messages to the display.
As trailers are usually not permanently powered, it is possible that due to the frequency of sensor
transmission the tire pressure data for all the wheels of the trailer is not available in the display for up to
21 minutes after starting the drive – depending on the sensor used.

19
System description
5.4 Expert’sreport/certicates
RFcerticates:
– Open the WABCO INFORM online product catalogue
http://inform.wabco-auto.com
– Use the product name OptiTire or IVTM to search the desired certicates.
– If you have any questions, please contact your WABCO partner.
Expert’s reports / Certicates for mounting and additional mounting of OptiTire are available, which
signicantly facilitate approval of vehicle registration papers. Customers must also include the relevant
details in the operating instructions.
5.4.1 ATEX
As the WM2 has its own battery and is attached to the outside of the wheel, it falls under the ATEX
directive to be used as explosion-proof equipment for potentially explosive gas atmospheres up to zone
1. It fulls the relevant requirements.
Expert’sreport/certicate
WM2: Associated EU type test certicate
TÜV 04 ATEX 2418 X
Application area ADR (G: potentially explosive gas atmospheres):
II 2G Ex ib IIC T4
The device is rated as being a small piece of electrical equipment, and therefore the marking
does not contain the complete information in accordance with directives or standards. The
manufacturer of the sensor is WABCO GmbH, Am Lindener Hafen 21, 30453 Hanover.
5.4.2 Radio approvals
The OptiTire components contain a radio transmitter for the 433 MHz ISM waveband. The output power
is less than 1 mW. The following approvals are available:
Expert’sreport/certicate
CE: 2014 / 53 / EU (RED)
FCC: Part 15
IC: RSS-210 Issue 8, RSS-GEN Issue 4, RSS-102 Issue 5

20
System description Components
5.4.3 OptiTire RF declaration of conformity
"This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
(1) This device may not cause harmful interference, and
(2) This device must accept any interference received, including interference that may cause undesired
operation"
"This device complies with Industry Canada’s licence-exempt RSSs. Operation is subject to the
following two conditions:
(1) This device may not cause interference; and
(2) This device must accept any interference, including interference that may cause undesired operation
of the device."
"Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio
exempts de licence. L’exploitation est autorisée aux deux conditions suivantes:
1) l’appareil ne doit pas produire de brouillage;
2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est
susceptible d’en compromettre le fonctionnement."
CAUTION TO USERS: "Changes or modications not expressly approved by the party
responsible for compliance could void the user’s authority to operate the equipment."